Contactor Circuits With Protective Circuitry For Three Phase Motors EST2

Contactor circuits with protective
circuitry for three phase motors
EST 2
230/400V 3/N/PE ~ 50 Hz
L1
L2
L3
N
PE
F1
1 3 5 1 3 5
Q1
k1 k2
Q2
2 6 2 4 6
4
Student workbook
SH5001-2B
Edition 2.1
Author: Lutz Schulz
Lucas-Nülle Lehr- und Messgeräte GmbH

Siemensstraße 2 • D-50170 Kerpen
Contactor circuits with protective systems for three
phase motors
Contents
Contactor circuit with latching relay ..........................................................................................1

Contactor circuit with latching relay & fault indication ...............................................................7
Contactor circuit with latched fault indication ..........................................................................13
Contactor circuit with time-delay relay (delayed drop out) ......................................................19
Contactor circuit with time-delay relay (delayed pull on) ........................................................25
Pulsed contactor circuit ..........................................................................................................31
Reversing contactor control with contactor interlock ..............................................................37
Reversing contactor control with contactor and button interlock ............................................43
Limit control with mechanical end-limit & reversing switches .................................................49
Star-delta circuit ......................................................................................................................55
Automatic star-delta circuit .....................................................................................................61
Automatic star-delta reversing circuit......................................................................................67
Pole changing circuit for two speeds (Dahlander) ..................................................................73
Pole changing circuit for two speeds (motor with two isolated windings) ...............................79
Contactor circuits with protective circuitry for three-phase
motors
Contactor circuit with latching relay

Aims of the Exercise
On completion of this exercise, students should be able to:
• Complete a diagram of the control circuit.
• Arrange the components for the main working circuit as specified in the circuit dia-
gram
• Read the motor’s current rating for a delta circuit from its rating plate and set up a
motor protection relay with this value.
• Connect up the components for the working and control circuits as specified in the
circuit diagrams and start the motor.
• Explain the purpose of switching contacts in a control circuit.
• Deduce from the circuit diagram that the main contacts of the contactor switch the
motor on.
EST 2/1 CONTACTOR CIRCUIT WITH LATCHING RELAY 1

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Circuit diagram
Fig. 1.1 Circuit diagram for working circuit
2 EST 2/1 CONTACTOR CIRCUIT WITH LATCHING RELAY

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Equipment/Components
1 Three-phase asynchronous motor with squirrel cage rotor

1 Contactor, 3 pole, 1 n. o. contact
1 Circuit breaker, single pole
3 Push-buttons each with 1 n. o. & 1 n. c. contact
1 Motor protection relay + auxiliary contact, 1 n. o. and 1 n. c. contact
2 Shaft covers
1 Mains circuit breaker, 3-pole
Introduction
A three-phase, delta-connected, asynchronous motor is to be switched on and off by means

of a contactor. The motor is to be protected against overload by a motor protection relay.
When button S1 is pressed, current flows through circuit branch 1 and contactor Q1 is ener-
gised. The contactor turns on, closing the latching contact of Q1 in circuit branch 2. This con-
tact remains closed when the button is released so that current can continue to flow through
the contactor coil. At the same time, the primary contacts in the main circuit close to connect
the motor to the 3-phase supply and so that motor is switched on.
If button S0 is pressed, then circuit branch 1 is broken and current ceases to flow. The con-
tactor coil is no longer energised so the contactor opens. The latching contact K1 in circuit
branch 2 also opens, as do the contacts in the working circuit so that the motor is turned off.

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Exercise
Complete this diagram for the control circuit.
Fig 1.2 Circuit diagram for control circuit

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Arrange the components as in the circuit diagram.
Wire up the components according to the diagrams for the working circuit and the control
circuit and connect the motor in a delta configuration. Adjust the motor protection relay to the
current rating for a delta circuit as quoted on the label on the motor.
Switch the motor on using the three-way push-button.
Give a short description of what would happen if a latching contact were not used.
Which push-button switches the motor on and which one switches the motor off?
Why is the n. c. contact F3 included in the control circuit? When does this contact open?
Which contacts connect the motor to the 3-phase supply?

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Contactor circuit with latching relay & fault indication

gram
• Simulate a fault condition that causes the motor protection relay to activate by loading
the motor with a magnetic powder brake.
• Specify when the fault indication lamp is lit.
EST 2/2 CONTACTOR CIRCUIT WITH LATCHING RELAY & FAULT INDICATION 7
Contactor circuits with protective circuitry for three phase
motors
Circuit diagram
Fig 2.1 Circuit diagram
8 EST 2/2 CONTACTOR CIRCUIT WITH LATCHING RELAY & FAULT INDICATION
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1 Contactor, 3-pole, 1 n. o. contact
1 Motor protection relay + auxiliary contact, 1 n. o. and 1 n. c. contact
2 Shaft covers
1 Indicator lamp
Introduction
A three-phase, delta-connected, asynchronous motor is to be switched on and off by means

of a contactor with a latching contact. In the case of a fault, the protective contactor should
open and an indicator lamp should indicate the fault condition. The motor is to be protected
against overload by a motor protection relay.
When button S1 is pressed, contactor Q1 is energised and the latching contact of Q1 in cir-
cuit branch 2 closes. At the same time, the primary contacts of the main circuit relay connect
the motor to the three-phase supply. The motor starts and the fault indicator lamp remains
off.
If button S0 is pressed, the control circuit is disconnected, Q1 opens as do the latching con-
tacts. At the same time, the main contacts of Q1 open and switch the motor off. The fault
indicator lamp remains off.
If a fault occurs (e. g. due an overload or one phase tripping out), then the current through
the motor exceeds the nominal value previously set on the protection relay. The contacts
associated with the bi-metal strip in the working circuit open and break the circuit. The motor
is switched off. At the same time, the change-over contacts of F2 in circuit branch 1 of the
control circuit switch the fault indicator lamp into circuit. The motor can be re-started only
after the bi-metal strip and the motor have cooled.
While this is happening, the n. c. contact of F3 opens, the n. o. contact of F3 closes and this
switches on the fault indicator lamp H1.
To provide a load for the motor the use of a hand operated magnetic powder brake is rec-
ommended. Adjustable speed and torque facilities are not necessary. If a magnetic powder
brake is not available, then the motor can be loaded by coupling it to a shunt or compound
generator. The generator is then loaded with a load resistor. Alternatively, one or more
phases can be disconnected from the terminal panel of the motor.
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Exercise
Complete this diagram of the control circuit.
Fig. 2.2 Circuit diagram for control circuit
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Switch the motor on and slowly increase the load on the motor by means of the magnetic
powder brake until it is overloaded and the protection relay trips out. Comment on the obser-
vations made.
Give a short description of the switch-on procedure and explain how the latching circuit
works.
Specify when the fault indicator lamp will be lit. In the case of a fault, can the motor be
switched on using switch S1?
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Contactor circuit with latched fault indication

gram
circuit diagrams, start the motor then reverse its direction.
• Simulate a fault condition that causes the motor protection relay to activate by loading
the motor with a magnetic powder brake.
• Explain how the fault condition is latched.
• Explain the advantage of latched fault indication.
EST 2/3 CONTACTOR CIRCUIT WITH LATCHED FAULT INDICATION 13

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Circuit diagram
Fig. 3.1 Circuit diagram
14 EST 2/3 CONTACTOR CIRCUIT WITH LATCHED FAULT INDICATION

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1 Auxiliary contactor, with 4 n. o. and 4 n. c. contacts
3 Push-button switches each with 1 n. o. & 1 n. c. contact
1 Motor protection relay with auxiliary contact, 1 n. o. & 1 n. c. contact
1 Indicator lamp
2 Shaft covers
Introduction
A delta-connected three-phase motor is to be operated via a circuit breaking contactor. A

motor protection relay is to protect the motor against overload.
If a fault occurs, it should be signalled by a fault indicator lamp. The lamp should be turned
off by operating button S2, irrespective of whether the protection relay has re-connected the
motor.
When push-button S1 is pressed, contactor Q1 closes so that current flows through circuit
branch 1. The latching contact of Q1 in circuit branch 2 ensures that the contactor remains
closed after switch S1 is released. The main contacts of Q1 are closed and the motor starts.
When push-button S0 is pressed, Q1 and circuit branch 1 both open. The latching contact in
circuit branch 2 also opens, as do the main contacts of Q1 so that the motor is switched off.
If the motor is overloaded, the current through the motor increases beyond the nominal value
set for the motor protection relay. The bi-metal strip in the working circuit opens and breaks
the circuit that supplies the motor, so that the motor is switched off. In the control circuit, the
n. c. contact of F3 opens while the n. o. contact of F3 closes, as does the auxiliary contactor
K11 in circuit branch 3. The latching contact of K11 in circuit branch 4 closes and prevents
the auxiliary contactor from opening up again. At the same time the K11 contact in circuit
branch 5 closes and the lamp lights up to indicate a fault condition. This indication is latched.
Once the bi-metal strip in the protection relay has cooled, the motor can be then switched on.
The auxiliary contactor K11 remains closed until push-button S2 is pressed, breaking circuit
branch 4. The K11 contact in circuit branch 5 open and the indicator lamp is switched off.
To provide a load for the motor, the use of a hand operated magnetic powder brake with or
without speed and torque sensors is recommended.

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If a magnetic powder brake is not available, then the motor can be loaded by coupling it to a
shunt, double shunt or compound generator. The generator is then loaded by means of a
load resistor. Alternatively, one or two of the phases can be disconnected from the terminal
panel of the motor.
Exercise

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Switch the motor on and slowly increase the load on the motor by means of the magnetic
powder brake until the protection relay trips out. Comment on the observations made.
Explain how the fault status is latched. What is the purpose of the K11 contact in circuit
branch 4?
Explain the advantages in having a latched fault indication as compared to a non-latched set-
up. When is it sensible to latch a fault condition?

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Contactor circuit with time-delay relay (delayed drop out)

gram
• Explain why the n. c. contact F3 of the motor protection relay cannot be a delayed ac-
tion contact.
• Be aware that the time-delay relay must be designed for long-term operation.
• Establish that the motor is switched off after a brief delay.
EST 2/4 CONTACTOR CIRCUIT WITH TIME-DELAY RELAY (DELAYED DROP OUT) 19
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Circuit diagram
20 EST 2/4 CONTACTOR CIRCUIT WITH TIME-DELAY RELAY (DELAYED DROP OUT)
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1 Time-delay relay, delayed drop-out
1 Indicator lamp
2 Shaft covers
Introduction
A three-phase motor is to be switched on via a contactor circuit and switched off via a de-
layed switching circuit. An indicator lamp is to signal the operating status of the motor. It
should be possible to set the time delay before the working contactor Q1 is switched off to
any required value.
When button S2 is pressed, the auxiliary contactor K 11 is energised and K11’s n. o. con-
tacts in circuit branches 2, 3 and 4 close. At the same time, the time-delay relay is energised
and the n. o. contact of K12 in circuit branch 4 is closed. The main contactor closes and
switches on the motor. The indicator lamp signals that the motor is on. K11’s n. o. contact in
circuit branch 2 is a latching contact for the time-delay relay K12 and the Q1 contact in circuit
branch 5 is a latching contact for contactor Q1.
When the normally closed switch S1 breaks circuit branch 1, the auxiliary contactor K11
drops out, the K11 contacts in circuit branches 2, 3 and 4 open and the indicator lamp is
switched off. The main contactor Q1 remains energised until the time-delay relay opens and
contact K12 breaks circuit branch 4. The motor is then switched off.
Switch S0 can be used in cases of emergency to disconnect the entire control circuit so that
the motor is switched off immediately.
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Exercise
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current rating for a delta circuit as quoted on the label on the motor. Set the delay on the
time-delay relay to approximately 10 seconds.
Switch on the motor. Alter the delay setting on the time-delay relay and repeat the switch-off
procedure.
Why must the n. c. contact of F3 in circuit branch 1 be connected in front of the control cir-
cuit?
Why must the time-delay relay be designed for long-term operation?
When does contact K12 in circuit branch 4 open?
Can the n. o. contact of K11 in circuit branch 2 be omitted from the circuit?
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Contactor circuit with time-delay relay (delayed pull on)

gram
• Observe that an auxiliary contactor is necessary to prevent the time-delay relay from
dropping out at switch-on.
• Explain why the delay relay must be designed for long-term operation.
• Comment on the purpose of the indicator lamp.
EST 2/5 CONTACTOR CIRCUIT WITH TIME-DELAY RELAY (DELAYED PULL ON) 25
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Circuit diagram
26 EST 2/5 CONTACTOR CIRCUIT WITH TIME-DELAY RELAY (DELAYED PULL ON)
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1 Time-delay relay, delayed pull-on
1 Indicator lamp
2 Shaft covers
Introduction
A three-phase motor is to be switched on via a delayed contactor circuit. An indicator lamp is

to signal the operating status of the motor. It should be possible to set the time delay before
the working contactor Q1 is switched on to any required value.
When button S1 is pressed, the contactor K11 and the delay relay K12 are energised. The
latching contact K11 in circuit branch 2 keeps contactor K11 and the time-delay relay K12
closed after S1 is released. At the same time an n. o. contact of K11 in circuit branch 5
closes and the indicator lamp H1 indicates that the circuit is switched on. After the delay, the
time-delay relay activates, the n. o. contacts of K12 in circuit branch 3 close and the auxiliary
contactor Q1 is energised. The motor is switched on. The latching contact Q1 in circuit
branch 4 prevents the main contactor Q1 from opening again.
When switch S0 is pressed, the entire control circuit is disconnected. The auxiliary contactor
K11, the working contactor Q1 and the time-delay relay K12 are all de-energised and the
motor is switched off.
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Exercise
Q1
Q1
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current rating for a delta circuit as quoted on the label on the motor. Set the delay on the
time-delay relay to approximately 10 seconds.
Switch on the motor. Alter the delay setting on the time-delay relay and repeat the switch-on
procedure.
What is the purpose of the auxiliary contactor K11 in circuit branch 1?
When does the n. o. contact of K12 operate?
Why must the time-delay relay be designed for long-term operation?
What is the purpose of the indicator lamp? Is the lamp necessary?
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Pulsed contactor circuit

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• Prove that only one push-button switch is necessary to switch the motor on and off,
• Observe that the auxiliary contactors must be interlocked.
• Explain why the auxiliary contactors need to have latching contacts.
EST 2/6 PULSED CONTACTOR CIRCUIT 31

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Circuit diagram
Q1
32 EST 2/6 PULSED CONTACTOR CIRCUIT

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1 Contactor, 3-pole with 2 n. o. auxiliary contacts and 1 n. c.
2 Auxiliary contactors
2 Shaft covers
Introduction
A three-phase motor is to be switched on and off via a circuit breaking contactor with a single
push-button switch.
When button S1 is pressed, circuit branch 1 is completed and the auxiliary contactor K11
closes. The n. o. contact of K11 in circuit branch 2 closes and ensures that the auxiliary con-
tactor of K11 remains closed for as long as switch S1 is pressed. The n. c. contact of K11 in
circuit branch 3 opens and interlocks auxiliary contactor K12 against being switched on from
switch S1. The n. o. contact of K11 in circuit branch 5 closes, as does the mains contactor
Q1, which remains latched on thanks to the n. o. contact of Q1 in circuit branch 6. The motor
is switched on. At the same time, the n. c. contact of Q1 in circuit branch 1 opens and the
n. o. contact of Q1 in circuit branch 3 closes.
The auxiliary contactor is then primed for a 2nd pulse (switch-off).
If switch S1 is pressed a second time, auxiliary contactor K12 becomes energised since cir-
cuit branch 3 is completed via the closed contacts of Q1 and K11. The auxiliary contactor
K12 is latched on by contact K12 in circuit branch 4 while button S1 is being pressed. The
n. c. contact of K12 in circuit branch 1 opens and interlocks the auxiliary contactor K11
against being switched on when S1 is pressed. The n. c. contact of K12 in circuit branch 5
opens as does the main contactor Q1, thus switching off the motor.

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Exercise
Q1
Q1 Q1
Q1

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current rating for a delta circuit (power diagram).
Switch on the motor.

How many push-buttons are necessary in order to be able to switch the motor on and off?
Why are the auxiliary contactors K11 and K12 interlocked?
Are the latching contacts of K11 and K12 necessary for the auxiliary contactors? Give rea-
sons for your answer.

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Reversing contactor control with contactor interlock

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• Explain why and how the contactors for clockwise and anti-clockwise rotation are in-
terlocked.
• Specify one disadvantage of this type of circuit that only interlocks the circuit by
means of contactors.
EST 2/7 REVERSING CONTACTOR CONTROL WITH CONTACTOR INTERLOCK 37

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Circuit diagram
38 EST 2/7 REVERSING CONTACTOR CONTROL WITH CONTACTOR INTERLOCK

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2 Contactors, 3-pole with 2 n. o. auxiliary contacts and 1 n. c.
2 Shaft covers
Introduction
A three-phase motor is to be switched on and off using a contactor circuit for clockwise and
anti-clockwise rotation. An interlock mechanism using contactors is to prevent reversal of
rotation whilst the motor is running.
If button S1 in circuit branch 1 is pressed, then the clockwise rotation contactor Q1 is ener-
gised and the motor switches on. At the same time, the latching contact of Q1 in circuit
branch 2 prevents contactor Q1 from being de-energised when S1 is released. The n. c. con-
tact of Q1 in circuit branch 3 will then be open so that contactor Q2 cannot be energised, i.e.
contactor Q2 is locked.
Pressing button S0 disconnects the entire control circuit. Contactor Q1 opens and its con-
tacts revert to their original position so that the motor is switched off.
Pressing S2 in circuit branch 3 energises anti-clockwise rotation contactor Q2 and switches

on the motor. Contactor Q2 is latched on by its Q2 contacts in circuit branch 4. At the same
time, the n. c. contact of Q2 in circuit branch 1 prevents contactor Q1 from being switched
on.
If button S0 in circuit branch 1 is pressed, the control circuit is disconnected. Contactor Q2

opens and its contacts revert to their original position so that the motor is switched off.
If both buttons S1 and S2 are pressed simultaneously there is a possibility of both contactors
Q1 and Q2 energising at the same time, thus causing a short circuit between live conductors
L1 and L3. To increase safety, an extra switch interlock circuit can be included.

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Exercise
Complete this diagram of the control circuit

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Switch on the motor and allow it to run in either direction.
When and how are the contactors Q1 and Q2 locked out?
Why are the contactors for clockwise and anti-clockwise rotation interlocked? (Refer to the
working circuit.)
Specify one disadvantage of this circuit as regards the locking method.

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Reversing contactor control with contactor and button

interlock
gram
• Be aware of the necessity for interlocking.
• Show that it is not possible to reverse of the direction of rotation directly without using
the off switch.
• Be aware of the advantages of interlocking both buttons and contactors.
EST 2/8 REVERSING CONTACTOR CONTROL WITH CONTACTOR AND BUTTON INTERLOCK 43
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Circuit diagram
44 EST 2/8 REVERSING CONTACTOR CONTROL WITH CONTACTOR AND BUTTON INTERLOCK
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2 Contactors, 3-pole, each with 2 n. o. auxiliary contacts and 1 n. c.
2 Shaft covers
Introduction
A three-phase motor is to be switched on and off using a contactor circuit in such a way that
it can rotate either clockwise or anti-clockwise. An interlocking system involving both
switches and contactors is to prevent reversal whilst the motor is running.
When button S2 is pressed, circuit branch 1 is closed and contactor Q1 is energised. The
n. c. contact of S2 in circuit branch 3 locks out contactor Q2 and the motor runs in a clock-
wise direction. As soon as contactor Q1 closes, the n. c. contact of Q1 in circuit branch 3
opens and also locks out contactor Q2. Contactor Q1 is latched on via contact Q1 in circuit
branch 2.
If button S0 is pressed, the control circuit is disconnected, contactor Q1 opens and the motor
is switched off.
When button S1 is pressed, the n. c. contact of S1 in circuit branch 1 opens and the n. o.
contact S1 in circuit branch 3 closes. Contactor Q1 is locked out via the open n. c. contact of
S1. Contactor Q2 closes and the motor runs anti-clockwise. The latching contact of Q2 in
circuit branch 4 latches contactor Q2 on. The n. c. contact of Q2 in circuit 1 opens and locks
out contactor Q1.
When switch S0 is pressed, the control circuit is disconnected. Contactor Q2 opens and the
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Exercise
Complete this diagram of the control circuit
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Switch on the motor and allow it to run in either direction.
When and how are the contactors Q1 and Q2 locked out?
Why is it necessary for the contactors to lock each other out?
Is it possible to switch from clockwise to anti-clockwise rotation without using the off switch?
Is this circuit of any practical value?
What are advantages of a circuit where the buttons and contactors are interlocked as op-
posed to a circuit where only the contactors are locked?
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Limit control with mechanical end-limit & reversing

switches
gram
• Specify when the pilot lamps are switched on.
• Observe that the contactors must be interlocked for clockwise and anti-clockwise ro-
tation.
• Explain the symbol for the limit switch in the circuit diagram.
• Describe how the rotation of the motor is reversed.
EST 2/9 LIMIT CONTROL WITH MECHANICAL END-LIMIT & REVERSING SWITCHES 49
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Circuit diagram
50 EST 2/9 LIMIT CONTROL WITH MECHANICAL END-LIMIT & REVERSING SWITCHES
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2 Shaft covers
2 Indicator lamps
2 End-limit switches
Introduction
A three-phase motor is to be switched on and off by a contactor circuit. End-limit switches

are to be included so that at a pre-determined end of run, signalled by indicator lamps, the
motor is switched off. At each end, another button turns the motor back on but in such a way
that it rotates in the opposite direction. Such a circuit is used in the control of lifts, doors, etc.
When button S1 is pressed, the main contactor Q1 closes so that the motor switches on and
rotates in a clockwise direction. The latching contact of Q1 in circuit branch 2 prevents Q1
from being de-energised when S1 is released. At the same time, an interlock contact Q1 in
circuit branch 3 opens, so that the anti-clockwise contactor Q2 cannot be energised.
When the end-limit switch S3 is activated, the S3 contact in circuit branch 1 opens, contactor
Q1 opens in turn and the motor is switched off. Contact S4 in circuit branch 6 closes and the
indicator lamp H2 signals that the end position has been reached. At the same time, contact
S4 in circuit branch 3 closes.
When button S2 in circuit branch 3 is pressed, the main contactor Q2 closes and switches on
the motor so that it rotates anti-clockwise. The latching contact of Q2 in circuit branch 4
closes and prevents Q2 from opening when S2 is released. The interlock contact of Q2 in
circuit 1 prevents the motor being switched to clockwise rotation. Contact S4 in circuit branch
6 also opens so that indicator lamp H2 is switched off.
When the end-limit switch S4 is toggled, contact S4 in circuit branch 3 opens as does contac-
tor Q2, switching off the motor. At the same time, contact S3 in circuit branch 5 closes and
indicator lamp H1 signals that the other end-position has been reached. Contact S3 in circuit
branch 1 closes once again.
In case of emergency, the n. c. contact S0 in circuit branch 1 can be used to disconnect the
entire circuit so that the motor is immediately switched off.
Operate the limit switches by hand.
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Exercise
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current rating for a delta circuit (rating plate).
Switch on the motor so that it runs clockwise. Press the clockwise end-limit switch S3 and
the motor will stop. Then switch the motor back on so that it runs anti-clockwise. Press the
anti-clockwise end-limit switch S4. Check that the indicator lamps function correctly.
When do the indicator lamps light up for clockwise and anti-clockwise rotation?
Explain why it is not possible to switch contactor Q2 on when the motor is rotating clockwise.
Are the latching facilities for contactors Q1 and Q2 necessary?
What is the meaning of the upward pointing arrow at the side of the S4 contacts in circuit
branches 3 and 4?
How is the direction of rotation reversed (refer to the circuit diagram)?
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Star-delta circuit
gram
circuit diagrams, start the motor in a star configuration then swap it over to a delta
configuration.
• Identify when the motor is connected in star configuration and when it is delta con-
figuration.
• Be aware of the necessity of a contactor interlock.
• Establish that, for a delta circuit contactor, a latching contact is not necessary.
EST 2/10 STAR-DELTA CIRCUIT 55

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Circuit diagram
(Q1-Q3)
56 EST 2/10 STAR-DELTA CIRCUIT

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2 Shaft covers
Introduction
A three-phase motor is to be started in a star circuit and then switched over to a delta con-
figuration. The switch-over is to be achieved manually by means of a sequential circuit. This
means that initially, the star and mains contactors are switched on, then a switch-over is to
be made to a delta circuit when the motor is up to speed.
When button S2 in circuit branch 1 is pressed, the star contactor Q2 is energised. Circuit
branch 3 is closed by the n. o. contact of Q2 and the mains contactor is energised. Contactor
Q2 in circuit branch 4 opens and prevents contactor Q3 being switched on. The motor starts
to run in a star configuration.
As soon as the motor is up to speed, button S1 in circuit branch 1 is pressed and the star
contactor opens. The n. c. contact of Q2 in circuit branch 4 closes and the delta circuit con-
tactor is energised. The mains contactor Q1 remains energised throughout. The n. c. contact
of Q3 in circuit branch 1 opens and prevents contactor Q2 being switched on. The motor
runs in a delta configuration.
By means of button S0 in circuit branch 1, the entire control circuit can be disconnected so
that all active contactors are de-energised and the motor is switched off.
Star-delta circuits are used as an aid to starting motors when it is necessary for a motor to be
started with the load already applied.

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Exercise

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Start the motor in a star circuit and, when it is up to speed, switch over to a delta circuit.
Which contactors are active for the star circuit and which are active for the delta circuit?
Explain why the star and the delta contactors have to be interlocked with each other.
Why is a latching contact for the delta contactor Q3 unnecessary?
Which value has to be set on the motor circuit breaker to protect the motor in star configura-
tion as well?

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Automatic star-delta circuit

gram
• Establish that the star contactor and the relay are energised only during the start-up
phase and that once the pre-set delay on the relay has expired, both contactor and
relay then drop out.
• Be aware that the circuit is an automatic sequential circuit.
• Identify the interlocking contacts and explain why an interlocking circuit is necessary.
EST 2/11 AUTOMATIC STAR-DELTA CIRCUIT 61

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Circuit diagram
(Q1-Q3)
62 EST 2/11 EST 2/11 AUTOMATIC STAR-DELTA CIRCUIT

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2 Push-button switches each with 2 n. o. & 2 n. c. contacts
2 Shaft covers
Introduction
A three-phase motor is to be switched on by an automatic star-delta circuit. The control sys-

tem is to be implemented as a sequential circuit. Initially, a star contactor should switch on
the mains contactor, then a delay relay should switch the motor over to delta operation.
When the on-button S1 is pressed, then circuit branch 1 closes and the star contactor and
time-delay relay are energised. The n. c. contact of K2 in circuit branch 4 opens and locks
out the delta contactor K3. Contact K2 in circuit branch 3 closes, the mains contactor K1 is
energised and contact K1 in circuit branch 4 closes.
The motor runs in star configuration.
After the delay time set on the relay expires, the relay drops out and the n. c. contact of K12
in circuit branch 1 opens. The star contactor K2 is de-energised and the n. c. contact of K2 in
circuit branch 4 closes.
The delta contactor K3 energises and switches the motor to delta operation. The n. c. contact
of K3 in circuit branch 1 opens and locks out the star contactor K2.
The control circuit can be disconnected via button S0. The active contactors open up and the
The delay time set on the relay is determined by the starting conditions of the motor. Auto-
matic star-delta circuits provide assistance when starting motors.

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Exercise

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Switch on the motor. Adjust the delay on the relay and repeat the switch-on procedure.
Which contactors are energised when button S1 is pressed and when is the time-delay relay
switched on?
Does the time-delay relay have to be designed for long-term operation?
Can the motor be switched on in a delta circuit straight away? Give reasons for your answer.
Identify the interlock contacts for the star and for the delta contactors. Why is interlocking
necessary?

motors

motors
Automatic star-delta reversing circuit

gram
circuit diagrams and start the motor rotating clockwise or anti-clockwise.
• Be clear that the star contactor and the time-delay relay are only turned on during the
start phase.
• Identify the interlock contacts of the star and delta contactors.
• Be aware that the clockwise and the anti-clockwise contactors are interlocked.
• Explain what is meant by a sequential circuit.
EST 2/12 AUTOMATIC STAR-DELTA REVERSING CIRCUIT 67

motors
Circuit diagram
(Q1-Q4)
68 EST 2/12 AUTOMATIC STAR-DELTA REVERSING CIRCUIT

motors

2 Shaft covers
Introduction
A three-phase motor is to be operated in an automatic star-delta reversing circuit. The motor

should start up in star configuration and, after a set time delay, should switch over to a delta
circuit. This start-up procedure should apply to both clockwise and anti-clockwise rotation.
The contactors are to be interlocked in such a way that reversal is possible only after the ff-
switch is pressed. The automatic star-delta switching is performed by a sequential circuit.
When button S1 is pressed, circuit branch 1 is completed and the n. c. contact of S1 in circuit
branch 7 locks out contactor Q4 to prevent switching to anti-clockwise rotation. The star con-
tactor Q2 is energised and is latched on by contact Q2 in circuit branch 3. The n. c. contact
of Q2 in circuit branch 9 locks out the delta contactor to prevent switch on. The n. o. contact
of Q2 in circuit branch 4 closes so that the time-delay relay and clockwise contactor Q1 are
energised. The latching contact Q1 in circuit branch 6 keeps the clockwise contactor Q1 en-
ergised. The motor is connected in star configuration and starts to run in a clockwise direc-
tion. After the delay set on the time-delay relay has expired, contact K11 in circuit branch 1
opens and the star contactor is switched off. The latching contact Q2 in circuit 3 in circuit
branch 3 opens as does contact Q2 in circuit branch 4 and the time-delay relay is switched
off. The n. c. contact of Q2 in circuit branch 9 reverts to its rest position and switches on the
delta contactor Q3. The clockwise contactor Q1 remains on so that the motor is in delta-
configuration and rotates in a clockwise direction.
When switch S0 is pressed, the control circuit is disconnected. Whichever contactor was
active opens up and the motor is switched off.
When switch S2 is pressed, circuit closes and the n. c. contact of S2 in circuit branch 5 inter-
locks out the clockwise contactor Q1. The star contactor Q2 is energised and latches on. The
delta contactor Q3 is locked out via the n. c. contact of Q2 in circuit branch 9. Contact Q2 in
circuit branch 4 closes and switches on the time-delay relay K11 and the anti-clockwise con-
tactor Q4. The latter latches on via contact Q4 in circuit branch 8. The motor is connected in
star configuration and rotates anti-clockwise. After the set delay, the time-delay relay K11
switches off and contact K11 in circuit branch 1 opens. The star contactor also turns off. The
n. o. contacts 3, 4 and the n. c. contact of Q2 in circuit branch 9 revert to their initial positions
and the time-delay relay K11 switches off. The anti-clockwise contactor remains on. The
delta contactor Q3 is energised and is held on by contacts Q4 in circuit 10. The motor is con-
nected in delta configuration and rotates anti-clockwise.

motors
When switch S0 is pressed, the entire control circuit is disconnected. Whichever contactor
was active releases and the motor is switched off.
Exercise
Fig. 12.2 Current diagram for control circuit

motors
Switch on the motor so that it rotates clockwise then switch it over to anti-clockwise rotation.
Adjust the delay on the relay and switch the motor back to clockwise rotation again before
altering the direction once more.
At what stage is the delay relay switched on?
Identify the interlock contacts for delta and star contactors.
How are the anti-clockwise and clockwise rotation contactors interlocked?
Why must the contactors for anti-clockwise and clockwise be interlocked?
What is meant by a sequential circuit?

motors

motors
Pole changing circuit for two speeds (Dahlander)

• Assemble a Dahlander pole changing circuit from the diagram given of the working
circuit and the completed diagram of the control circuit and effect a speed change.
• Recognise from the circuit diagrams that the contactor Q1 is used for low speeds and
that the contactors Q2 and Q3 are used for higher speeds.
• Be aware that the contactors for the various speeds must be interlocked.
EST 2/13 POLE CHANGING CIRCUIT FOR TWO SPEEDS (DAHLANDER) 73

motors
Circuit diagram
(Q1-Q3)
74 EST 2/13 POLE CHANGING CIRCUIT FOR TWO SPEEDS (DAHLANDER)

motors
1 Three-phase asynchronous motor with squirrel cage rotor, Dahlander pole changing
2 Motor protection relays with auxiliary contact, 1 n. o. & 1 n. c. contact
2 Shaft covers
Introduction
In this Dahlander-type pole changing circuit, the motor windings are delta-connected for low
speeds and are connected in double-star configuration for higher speeds. Speed changes
can only be effected in incremental steps. For the motor available for this exercise, the speed
is changed in the ratio of 1:2.
In the control circuit used, the contactors are interlocked so that only 1 speed can be se-
lected.
When button S2 (n. o. contacts) is operated, contactor Q1 is energised via the closed con-
tacts of Q2 and Q3 in circuit branch 1. The main contacts of contactor Q1 complete the work-
ing circuit and the motor is switched on at low speed. At the same time, the latching contact
in circuit branch 2 and the interlocking (n. c.) contact Q1 in circuit branch 3 are opened.
When button S3 is operated, circuit branch 1 is broken and contactor Q1 drops out. At the
same time, contactors Q2 and Q3 are energised via the n. o. contact S3 in circuit branch 3.
The self-holding contact Q2 in circuit branch 4 closes and keeps contactors Q2 and Q3 en-
ergised. The n. c. contacts of Q2 and Q3 in circuit branch 1 are now open and Q1 is locked
out. The main contacts of contactors Q2 and Q3 close and the motor runs at a higher speed
in a double-star configuration.
When button S1 is pressed, the circuits all are disconnected and all contactors drop out. The

motors
Exercise

motors
Arrange the components as in the circuit diagram 13.1 and wire up the components accord-
ing to the diagrams for the working circuit 13.1 and the completed control circuit.
Switch on the motor and change its speed.
What is the purpose of the motor protection relay?
What speed is selected by the main contacts of the Q1 contactor? How are the windings of
the Dahlander motor configured when switched on by this contactor?
What is the purpose of the contactor Q3 and how are the motor windings connected?
What is the purpose of the n. c. contacts of Q2 and Q3 in circuit branch 1?
What is the purpose of the n. o. contact of Q1 in circuit branch 2?
What happens if button S2 is pressed whilst the motor is running at high speed?
What is the purpose of the n. c. contact of Q1 in circuit branch 3?

motors

motors
Pole changing circuit for two speeds

(motor with two windings)
gram
circuit diagrams and start the motor rotating at the two possible speeds.
• Specify the number of pole pairs used in low and in high speed running.
• Be aware that the motor windings for the two speeds are interlocked with each other
via both switch and the contactor circuits.
• Explain why a motor protection relay is necessary for each motor winding.
EST 2/14 POLE CHANGING CIRCUIT FOR TWO SPEEDS (MOTOR WITH TWO ISOLATED WINDINGS) 79
motors
Circuit diagram
80 EST 2/14 POLE CHANGING CIRCUIT FOR TWO SPEEDS (MOTOR WITH TWO ISOLATED WINDINGS)
motors
1 Three-phase asynchronous motor with squirrel cage rotor, 2 isolated windings

3 Motor protection relays with auxiliary contact, 1 n. o. & 1 n. c. contact
2 Shaft covers
Introduction
A three-phase asynchronous motor with 2 separate and isolated windings is to be connected

to a pole-changing contactor for operation at low and high speeds. The motor for this exer-
cise has 2 separate windings with 2 pole-pairs for high speed running and 4 for low speed.
The pole pair number determines the motor speed according to the expression below:
f = Frequency in Hz
60 f
n= p = No. of pole pairs
p n = Speed in rpm
When loaded, the motor responds in the same way as an asynchronous motor with one sta-
tor winding. It must be pointed out that only one speed change increment is possible.
Asynchronous motors with 2 separate windings are used where several pre-determined
speeds are required, e.g. mixers, pumps, fans and machine tools.
When button S1 is pressed, circuit branch 1 is completed and the n. c. contact of S1 in circuit
branch 3 opens. Contactor Q1 is energised and the motor runs at low speed. Contactor Q1 is
latched on by its own n. o. contact Q1 in circuit branch 2 when the button S1 is released. The
n. c. contact of Q1 in circuit branch 3 opens and locks out contactor Q2 so that it cannot be
turned on.
When button S2 is operated, circuit branch 1 is broken and contactor Q1 drops out. At the
same time, the n. o. contact of S2 in circuit branch 3 closes and contactor Q2 is energised.
The motor runs at high speed. When switch S2 is released, contactor Q2 is held on by its
own latching contact (n. o.) Q2 in circuit branch 4. The n. c. contact Q2 in circuit branch 1
opens and locks out contactor Q1.
If button S0 is operated, the entire control circuit is disconnected, the active contactor drops
out and the motor is switched off.
motors
Exercise
82 EST 2/14 POLE CHANGING CIRCUIT FOR TWO SPEEDS (MOTOR WITH TWO ISOLATED WINDINGS)
motors
Arrange the components as in the circuit diagram for the main working circuit.
circuit. Adjust the motor protection relays to the current rating for high speed and low speed.
Switch on the motor at low speed. Change the speed of the motor.
How many pole pairs does the motor winding for low speed running have?
Which winding is connected in circuit when contactor Q2 is energised?
How are the two speeds interlocked?
Why are 2 motor protection relays necessary?
motors
Working together with you and for you:

Your personal experience and observations can contribute to improvements to this product
and the elimination of any errors. Your comments will be of considerable importance to us in
future revisions of our manuals.
We wish to thank you for your interest and your

cooperation.
Reg.: Manual
Notes:
Date:
Copyright © 2010 LUCAS-NÜLLE GmbH. All rights reserved.
This manual is protected by copyright. All rights pertaining thereto are reserved. Any reproduction of
this document as a file or in written form be it photocopy, microfilm or any other method or conversion
into a machine-compatible language, in particular for data processing systems, without the expressed
written approval of the LUCAS-NÜLLE GmbH is strictly forbidden.
The one specific exception to the above is the reproduction of worksheets for students to be used
entirely within the organisation that has purchased this resource and solely for the purposes of
education. Such worksheets may be reproduced in any numbers as long as no alterations to the
content are made.
If changes have been performed in a manner which was not strictly authorised by the LUCAS-NÜLLE
GmbH, any product liability or warranty claims pertaining thereto are null and void.
LUCAS-NÜLLE Lehr- und Meßgeräte GmbH

Address: Siemensstraße 2 • D-50170 Kerpen (Sindorf)
Postal address: Postfach 11 40 • D-50140 Kerpen
Tel.: 02273 / 567-0 • Fax: 02273 / 567-30 • E-mail: vertrieb@lucas-nuelle.com
FEEDBACK
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Lucas-Nülle Lehr- und Meßgeräte GmbH

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Telefon +49 2273 567-0 · Fax +49 2273 567-30
www.lucas-nuelle.de

Contactor Circuits With Protective Circuitry For Three Phase Motors EST2

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Contactor Circuits With Protective Circuitry For Three Phase Motors EST2

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Contactor circuits with protective

circuitry for three phase motors

Author: Lutz Schulz

Lucas-Nülle Lehr- und Messgeräte GmbH

Contactor circuit with latching relay ..........................................................................................1

Contactor circuit with latching relay

On completion of this exercise, students should be able to:

• Complete a diagram of the control circuit.

• Explain the purpose of switching contacts in a control circuit.

EST 2/1 CONTACTOR CIRCUIT WITH LATCHING RELAY 1

Fig. 1.1 Circuit diagram for working circuit

2 EST 2/1 CONTACTOR CIRCUIT WITH LATCHING RELAY

1 Three-phase asynchronous motor with squirrel cage rotor

A three-phase, delta-connected, asynchronous motor is to be switched on and off by means

EST 2/1 CONTACTOR CIRCUIT WITH LATCHING RELAY 3

Complete this diagram for the control circuit.

Fig 1.2 Circuit diagram for control circuit

4 EST 2/1 CONTACTOR CIRCUIT WITH LATCHING RELAY

Arrange the components as in the circuit diagram.

Switch the motor on using the three-way push-button.

Which contacts connect the motor to the 3-phase supply?

EST 2/1 CONTACTOR CIRCUIT WITH LATCHING RELAY 5

6 EST 2/1 CONTACTOR CIRCUIT WITH LATCHING RELAY

Contactor circuit with latching relay & fault indication

On completion of this exercise, students should be able to:

• Complete a diagram of the control circuit.

• Specify when the fault indication lamp is lit.

Fig 2.1 Circuit diagram

1 Three-phase asynchronous motor with squirrel cage rotor

A three-phase, delta-connected, asynchronous motor is to be switched on and off by means

Complete this diagram of the control circuit.

Fig. 2.2 Circuit diagram for control circuit

Arrange the components as in the circuit diagram.

Contactor circuit with latched fault indication

On completion of this exercise, students should be able to:

• Complete a diagram of the control circuit.

• Explain how the fault condition is latched.

• Explain the advantage of latched fault indication.

EST 2/3 CONTACTOR CIRCUIT WITH LATCHED FAULT INDICATION 13

Fig. 3.1 Circuit diagram

14 EST 2/3 CONTACTOR CIRCUIT WITH LATCHED FAULT INDICATION

1 Three-phase asynchronous motor with squirrel cage rotor

A delta-connected three-phase motor is to be operated via a circuit breaking contactor. A

EST 2/3 CONTACTOR CIRCUIT WITH LATCHED FAULT INDICATION 15

Complete this diagram of the control circuit.

Fig. 3.2 Circuit diagram for control circuit

16 EST 2/3 CONTACTOR CIRCUIT WITH LATCHED FAULT INDICATION

Arrange the components as in the circuit diagram.

EST 2/3 CONTACTOR CIRCUIT WITH LATCHED FAULT INDICATION 17

18 EST 2/3 CONTACTOR CIRCUIT WITH LATCHED FAULT INDICATION

Contactor circuit with time-delay relay (delayed drop out)

On completion of this exercise, students should be able to:

• Complete a diagram of the control circuit.

• Establish that the motor is switched off after a brief delay.

Fig. 4.1 Circuit diagram

1 Three-phase asynchronous motor with squirrel cage rotor

Complete this diagram of the control circuit.

Fig. 4.2 Circuit diagram for control circuit

Arrange the components as in the circuit diagram.

Why must the time-delay relay be designed for long-term operation?

When does contact K12 in circuit branch 4 open?

Contactor circuit with time-delay relay (delayed pull on)

On completion of this exercise, students should be able to: